New Aircraft Will Utilize Composite Materials

Aerospace companies Boeing and Airbus are working on developing new components to aid in developing new aircraft structures. Forecasts of aircraft sales show that the worldwide demand of large passenger airplanes will increase and an overall production number of up to 40,000 new aircraft may be realized in the next 20 years. To meet this new demand, Boeing and Airbus are working on developing new honeycomb panels that are designed to be structurally stiff, strong, and importantly, easy to assemble and produce. For the increase in aircraft demand, new aircraft structures must be easy to assemble and sub-components must be manufactured rapidly. The new structure composites or sandwiches are being developed for Boeing and Airbus by Belgium Company EconCore, along with Diehl Aircabin. The sandwich structures consist of a lightweight inner honeycomb lattice that is sandwiched between two thin layers of either aluminum or other lightweight material, to create a structure that is lightweight, strong, and has excellent thermal insulating qualities. Insulating against the cold external atmosphere while aircraft are in flight is crucial for passenger comfort and safety. In addition to the insulating properties, the inner honeycomb lattice can be made out of lightweight polycarbonate to create an excellent fire barrier within the sandwich structure. Polycarbonate is strong and resists flammability, making it a good choice for many aircraft structures. The process developed by EconCore can be formed into many different shapes; however joining the layers of the sandwich material together may pose another problem. To remedy this issue, new formulae of bonding adhesives are being developed to properly secure the components together. The benefit of using bonding adhesives instead of traditional rivets, screws, or other hardware, is the weight savings, however ensuring that the bonds between composite components remains solid for the life of the aircraft is being tested before it is put into production. -taken from www.sae.org

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Joe Tremblay

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